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ABB ACS880-07CLC Hardware Manual
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ABB ACS880-07CLC Hardware Manual

ABB ACS880-07CLC Hardware Manual

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ABB INDUSTRIAL DRIVES
ACS880-07CLC drives
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  • Page 1 — ABB INDUSTRIAL DRIVES ACS880-07CLC drives Hardware manual...
  • Page 3 ACS880-07CLC drives Hardware manual Table of contents 1. Safety instructions 4. Mechanical installation 10. Start-up 3AXD50000131457 Rev C Original instructions EFFECTIVE: 2024-06-14...

  • Page 5: Table Of Contents

    Table of contents 5 Table of contents 1 Safety instructions Contents of this chapter ............... . Use of warnings and notes .
  • Page 6 6 Table of contents Cabinet heater with external supply (option +G300) ........Cabinet lighting (option +G301) .
  • Page 7 Additional requirements for braking applications ....... . . Additional requirements for ABB high-output and IP23 motors ....
  • Page 8 8 Table of contents Protecting the motor against overload without thermal model or temperature sensors ..................Protecting the drive against ground faults .
  • Page 9 Table of contents 9 Use of fasteners in cable lug connections ..........Connecting the control cables .
  • Page 10 10 Table of contents BCU, ZCU-14 connector data ..............Connector data .
  • Page 11 Table of contents 11 Ratings ....................Definitions .
  • Page 12 ACS880-07CLC-1310A-7 ..............ACS880-07CLC-2180A-7 +C121 (marine construction) ......
  • Page 13 Table of contents 13 Single-channel connection of activation switch (UCU) ....... Single-channel connection of activation switch (BCU) .

  • Page 15: Safety Instructions

    Safety instructions 15 Safety instructions Contents of this chapter This chapter contains the safety instructions which you must obey when you install, start-up, operate and do maintenance work on the drive. If you ignore the safety instructions, injury, death or damage can occur. Use of warnings and notes Warnings tell you about conditions which can cause injury or death, or damage to the equipment.

  • Page 16: General Safety In Installation, Start-Up And Maintenance

    16 Safety instructions General safety in installation, start-up and maintenance These instructions are for all persons who do work on the drive. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. •...
  • Page 17 Safety instructions 17 • Beware of hot surfaces. Some parts, such as heatsinks of power semiconductors, and brake resistors, can be hot for a period after operation. • Make sure that debris from drilling, cutting and grinding does not go into the drive during installation.

  • Page 18: Work On The Liquid Cooling System

    • If you need to store the drive in temperature below -15 °C (5 °F), drain the cooling circuit, or make sure that it is filled with the coolant specified by ABB. • Drives with the cooling unit: Do not open the cooling unit pump inlet or outlet valves before filling up the coolant circuit.

  • Page 19: Electrical Safety In Installation, Start-Up And Maintenance

    Safety instructions 19 Electrical safety in installation, start-up and maintenance Electrical safety precautions ￭ These electrical safety precautions are for all persons who do work on the drive, motor cable or motor. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur.
  • Page 20 20 Safety instructions structures, obey the local laws and regulations applicable to live electrical work. This includes, but is not limited to, electric shock and arc protection. • Before and after you measure the installation, verify the operation of the voltage tester on a known voltage source.

  • Page 21: Additional Instructions And Notes

    The equipment produces electromagnetic fields that can cause interference in electronic medical devices. This can cause a health hazard. • ABB does not recommend attaching the cabinet by arc welding. If you have to, obey the welding instructions in the drive manuals. Note: •...

  • Page 22: Grounding

    22 Safety instructions Grounding ￭ These instructions are for all persons who are responsible for the grounding of the drive. WARNING! Obey these instructions. If you ignore them, injury or death, or equipment malfunction can occur, and electromagnetic interference can increase. If you are not a qualified electrical professional, do not do grounding work.

  • Page 23: General Safety In Operation

    Safety instructions 23 General safety in operation These instructions are for all persons that operate the drive. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. • Keep the cabinet doors closed when the drive has electrical power. If the doors the drive cabinet are open, there is a risk of a potentially fatal electric shock, arc flash or high-energy arc blast exists.

  • Page 24: Additional Instructions For Permanent Magnet Motor Drives

    24 Safety instructions Additional instructions for permanent magnet motor drives Safety in installation, start-up, maintenance ￭ These are additional warnings for permanent magnet motor drives. The other safety instructions in this chapter are also valid. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur.

  • Page 25: Introduction To The Manual

    Introduction to the manual 25 Introduction to the manual Contents of this chapter This chapter describes the manual. It contains a flowchart of steps in checking the delivery, installing and starting up the drive. The flowchart refers to chapters/sections in this manual and to other manuals. Target audience This manual is intended for people who plan the installation, install, commission and do maintenance work on the drive, or create instructions for the end user of the drive...

  • Page 26: Use Of Component Designations

    26 Introduction to the manual Use of component designations Some device names in the manual include the component designation in brackets (for example, [Q20]). This will help you to identify the components in the circuit diagrams of the drive. Quick installation, commissioning and operation flowchart Task Electrical planning (page 75) Plan the electrical installation and acquire the accessories...

  • Page 27: Terms And Abbreviations

    Frame, frame Physical size of the drive or power module size FSO-12, FSO-21 Functional safety modules (not available for the ACS880-07CLC at the time of publishing) IGBT Insulated gate bipolar transistor Inverter unit Inverter module(s) under control of one control unit, and related components. One in- verter unit typically controls one motor.

  • Page 29: Operation Principle And Hardware Description

    Contents of this chapter This chapter briefly describes the operation principle and construction of the drive. Operation principle The ACS880-07CLC is a liquid-cooled cabinet-installed drive for controlling asynchronous AC induction motors, permanent magnet synchronous motors and AC induction servomotors. The drive consists of several cubicles that contain the supply and motor terminals, 1 to 8 diode supply module(s), 1 to 8 inverter modules, and optional equipment.

  • Page 30: Charging

    30 Operation principle and hardware description • The installer must arrange for overload and short-circuit protection of the supply cable, typically with fuses. • The supply unit of the drive does not have AC or DC chokes. Therefore, the installer must arrange for a sufficient inductance at the AC side of each supply module with suitable cabling.

  • Page 31: Overview Diagrams

    Operation principle and hardware description 31 Overview diagrams ￭ This section contains examples of main circuit overview diagrams. The diagrams show the power line connection, and the connections between the parts of the drive. Overview diagram of the drive AC supply. See detailed diagrams below. AC fuses.
  • Page 32 32 Operation principle and hardware description Supply connection detail – one D8D module, 6-pulse connection, internal charging Medium voltage / low voltage switchboard External installation outside drive cabinet Supply transformer Charging switchgear including: • Disconnecting device Dedicated supply switchgear including: •...
  • Page 33 Operation principle and hardware description 33 Supply connection detail – two D8D modules, 6-pulse connection, internal charging Medium voltage / low voltage switchboard External installation outside drive cabinet Supply transformer Charging switchgear including: • Disconnecting device Dedicated supply switchgear including: •...
  • Page 34 34 Operation principle and hardware description Supply connection detail – two D8D modules, 12-pulse connection, internal charging Medium voltage / low voltage switchboard External installation outside drive cabinet Supply transformer Charging switchgear including: • Disconnecting device Interlocked, dedicated supply switchgear including: •...
  • Page 35 Operation principle and hardware description 35 Supply connection detail – two D8D modules, 6-pulse connection, external charging and pre-magnetizing Medium voltage / low voltage switchboard External installation outside drive cabinet Switchgear including: • Disconnecting device • Breaker/contactor Combined transformer pre-magnetizing circuit and drive charging circuit Supply transformer Overcurrent and short-circuit protection of input cabling Supply module cubicle of drive...
  • Page 36 36 Operation principle and hardware description Supply connection detail – two D8D modules, 12-pulse connection, external charging and pre-magnetizing Medium voltage / low voltage switchboard External installation outside drive cabinet Switchgear including: • Disconnecting device • Breaker/contactor Combined transformer pre-magnetizing circuit and drive charging circuit Supply transformer Overcurrent and short-circuit protection of input cabling Supply module cubicle of drive...

  • Page 37: 6-Pulse, 12-Pulse And 24-Pulse Connections

    Operation principle and hardware description 37 6-pulse, 12-pulse and 24-pulse connections ￭ The figure below illustrates the difference between 6-pulse and 12-pulse AC supply connections. 6-pulse connection is standard. Some drive types are available as a 12-pulse version (option +A004), some as a 24-pulse version (option +A006).

  • Page 38: Cabinet Line-Up And Layout Examples

    38 Operation principle and hardware description Cabinet line-up and layout examples ￭ Frame 2×D8D+2×R8i Frame 3×D8D+3×R8i...
  • Page 39 Operation principle and hardware description 39 Description Supply module cubicle Inverter module cubicle Optional liquid cooling unit. See ACS880-1007LC liquid cooling unit user's manual (3AXD50000129607 [English]). Swing-out frame for installation of control equipment. The frame is hinged and can be turned aside.
  • Page 40 40 Operation principle and hardware description (Behind the swing-out frame) Inverter modules Inverter control unit. See chapter Control unit (UCU) (page 133)or Control units (BCU and ZCU) (page 147)). Air-to-liquid heat exchanger installed below each inverter module. See chapter Internal cooling circuit (page 269).

  • Page 41: Overview Of Power And Control Connections

    Operation principle and hardware description 41 Overview of power and control connections The diagram shows the power connections and control interfaces of the drive. Drive Supply control unit (A51) Inverter control unit (A41) Slots 1, 2 and 3 Slot 4 X205 V1T/R…...

  • Page 42: Control Units

    42 Operation principle and hardware description Terminal blocks for customer connections installed in the drive cabinet. Supply unit (consisting of one or more supply modules) DC intermediate link Inverter unit (consisting of one or more inverter modules) Control units The supply unit of the drive is controlled by a dedicated ZCU-14 control unit (component designation A51).

  • Page 43: Control Panel

    Operation principle and hardware description 43 Control panel ￭ The ACS-AP-W is the user interface of the drive. It provides the essential controls such as Start/Stop/Direction/Reset/Reference, and the parameter settings for the inverter control program. The control panel can be removed by pulling it forward by the top edge and reinstalled in reverse order.

  • Page 44: Marine Construction (Option +C121)

    44 Operation principle and hardware description Marine construction (option +C121) ￭ The option includes the following accessories and features by default: • reinforced mechanics • grab railings • door flush bolt which allows the door to open 90 degrees and prevents it from slamming close •...

  • Page 45: Cabinet Lighting (Option +G301)

    Operation principle and hardware description 45 The heater prevents condensation inside the cabinet when the drive is not in operation. The power output of the heating elements increases when the surrounding air temperature is low and decreases when the surrounding air temperature is high. The customer must stop the heating when it is not needed by disconnecting the heater supply voltage.

  • Page 46: Additional Wire Markings

    46 Operation principle and hardware description • Main circuit terminals: Connector identifier (eg. "U1") marked on terminal, or on insulating material close to the terminal. Input and output main circuit cables are not marked. • Plug-in connectors of wire sets (except those that require special tools to disconnect) are labeled with connector designation (eg.

  • Page 47: Bottom Cable Entry/Exit (Options +H350 And +H352)

    Operation principle and hardware description 47 Option Additional markings +G342 Single wires connected to components, between modules, or to terminal blocks are (class C1) marked with component identification and pin numbers for both ends. The marking is printed on sleeving or, if necessary, snap-on markers. Plug-in connectors are marked with an identification label (or snap-on markers) placed on the wires near the connector (individual wires are not marked).

  • Page 48: Roxtec Cable Entry (Option +H394)

    ￭ The cabinet can be equipped with a multi-cable transit frame for Roxtec cable entry (option +H394). ABB provides only the frames, not the seals or the installation tools. For sealing components and installation instructions, refer to www.roxtec.com. The figure below shows a bottom cable entry frame and and an example of a sealing module for a W600 cabinet.

  • Page 49: Additional Terminal Block X504 (Option +L504)

    Operation principle and hardware description 49 Designed for Cable frame Roxtec frame Description ACS880LC W600 3AUA5000295764 GHM 8X1 AISI316 Roxtec frame with integrated flange. Additional terminal block X504 (option +L504) ￭ The standard terminal blocks of the drive control unit are wired to the additional terminal block at the factory for customer control wiring.

  • Page 50: Type Designation Key

    50 Operation principle and hardware description Jl 1111 ACSBB0-07CLC-1470A-7+A0 12+A0 19+B054+C138+ r,1•1• C140+C143+C149+E205+E210+F250+F�72+G300+ G301+G313+G315+G316+G320+G340+G436+H350+ H352+H359+H367+J400+K450+K454+2L500+L503 MADE IN FINLAND +5L506+L509+L515+M634+N8010+Q951 �fo':n�l.e 13 00380 Helsinki Input Finland U1 3~ 525/600/690 VAC 1345 A 50/60 Hz FRAME Output U2 3~ 0 ... U1 2xO8D 1470 A +2xRBi...
  • Page 51 Operation principle and hardware description 51 Code Description A006 24-pulse supply connection A012 50 Hz supply frequency A013 60 Hz supply frequency B054 IP42 (UL Type 1 Filtered) B055 IP54 (UL Type 12) C121 Marine construction. See section Marine construction (option +C121) (page 44).
  • Page 52 52 Operation principle and hardware description Code Description G331 Emergency stop push button on the door (red) G338 Wire marking class A1. See section Wire markings (page 45). G339 Wire marking class A2. See section Wire markings (page 45). G340 Wire marking class A3.
  • Page 53 Operation principle and hardware description 53 Code Description M601 Starter for auxiliary motor fan, trip limit 1.6 … 2.5 A M602 Starter for auxiliary motor fan, trip limit 2.5 … 4 A M603 Starter for auxiliary motor fan, trip limit 4 … 6.3 A M604 Starter for auxiliary motor fan, trip limit 6.3 …...

  • Page 55: Mechanical Installation

    Mechanical installation 55 Mechanical installation Contents of this chapter This chapter tells how to examine the installation site, unpack and examine the delivery and install the drive mechanically. Examining the installation site Examine the installation site. Make sure that: • The installation site is sufficiently ventilated or cooled to remove heat from the drive.

  • Page 56: Examining The Delivery

    56 Mechanical installation • torque wrench • set of wrenches or sockets. Examining the delivery The drive delivery contains: • drive cabinet line-up • optional modules (if ordered) installed onto the control unit(s) at the factory • appropriate drive and optional module manuals •...

  • Page 57: Moving The Drive In Its Packaging

    Mechanical installation 57 Moving the drive in its packaging ￭ Lifting the crate with a forklift WARNING! Obey the local laws and regulations that apply to lifting, such as the requirements for planning the lift, the capacity and condition of the lifting equipment, and personnel training.

  • Page 58: Lifting The Crate With A Crane

    58 Mechanical installation Lifting the crate with a crane WARNING! Obey the local laws and regulations that apply to lifting, such as the requirements for planning the lift, the capacity and condition of the lifting equipment, and personnel training. Lifting point Optimal position for the lifting sling: as close to the traverse board as possible...

  • Page 59: Moving The Crate With A Forklift

    Mechanical installation 59 Mechanical installation 61 Moving the crate with a forklift Moving the crate with a forklift 750 mm (29.5'') Removing the transport package ￭ Remove the transport package as follows: Undo the screws that attach the wooden parts of the transport crate to each other.

  • Page 60: Moving The Unpacked Drive Cabinet

    62 Mechanical installation Removing the transport package  60 Mechanical installation Remove the transport package as follows: 1. Undo the screws that attach the wooden parts of the transport crate together. Moving the unpacked drive cabinet ￭ 2. Remove the wooden parts. Lifting the cabinet with a crane 3.

  • Page 61: Moving The Cabinet On Its Back

    Mechanical installation 61 Lay the cabinet on the rollers and move it carefully until close to its final location. Remove the rollers by lifting the unit with a crane, forklift, pallet truck or jack. Moving the cabinet on its back Support the cabinet from below alongside the cubicle seams.

  • Page 62: Attaching The Cabinet To The Floor And Wall Or Roof

    62 Mechanical installation Attaching the cabinet to the floor and wall or roof General rules ￭ • The drive must be installed in an upright vertical position. • Leave 250 mm (9.85”) of free space above the cabinet for maintenance, and to allow pressure relief operation.

  • Page 63: Attaching The Cabinet (Marine Units)

    Mechanical installation 63 Attaching the cabinet (marine units) ￭ See the dimension drawing delivered with the drive for details of the fastening points. Fasten the cabinet to the floor and roof (wall) as follows: Bolt the unit to the floor through the flat bars at the base of the cabinet using M10 or M12 screws.

  • Page 64: Joining Cabinet Sections Together

    64 Mechanical installation Joining cabinet sections together Wide cabinet line-ups are delivered in multiple sections. The sections must be joined together at the installation site. There is a joining cubicle at the end of a section for this purpose. The screws for joining the sections are in a plastic bag inside the cabinet. Attach the first section to the floor.
  • Page 65 Mechanical installation 65 Center the Axilock connectors onto the gaps between coolant pipe ends. Tighten the connector screws to the torque indicated on the connector label. Attach the front and rear posts of the joining cubicle to the posts of the other section with 16 screws (8 per post).
  • Page 66 66 Mechanical installation Connect the PE (ground) busbars using the M10 bolts included. Tighten to 35…40 N·m (25…30 lbf·ft). Side Above Plain washer Spring washer Bolt Remove the shroud covering the DC busbars in the joining cubicle.
  • Page 67 Mechanical installation 67 10. Connect the DC and AC busbars. Tighten the bolts to 55…70 N·m (40…50 lbf·ft). Units with single DC busbars Units with double DC busbars Accessories kit identification: Single DC busbars: 3AXD50000125876 Double DC busbars: 3AXD50000126361 Triple DC busbars (not shown): 3AXD50000126378 Joint piece Plain washer with electroplated zinc coating and blue chromate passivation Spring washer with mechanically sprayed zinc coating...
  • Page 68 68 Mechanical installation Units with single AC busbars Units with double AC busbars Accessories kit identification: Single AC busbars: 3AXD50000126392 Double AC busbars: 3AXD50000126408 Triple AC busbars (not shown): 3AXD50000126514 Bolt (M12) Bolt (M12) Joint piece Plain washer with electroplated zinc coating and blue chromate passivation Spring washer with mechanically sprayed zinc coating Nut (M12) WARNING!

  • Page 69: Miscellaneous

    Arc welding ￭ ABB does not recommend attaching the cabinet by arc welding. However, if arc welding is the only option, connect the return conductor of the welding equipment to the cabinet frame at the bottom within 0.5 meters (1’6”) of the welding point.

  • Page 70: Lifting Lugs And Bars

    70 Mechanical installation Lifting lugs and bars Certificate of conformity ￭ The certificate is available in ABB Library at www.abb.com/drives/documents (document number 3AXD10001061361). Declarations of conformity ￭...
  • Page 71 Mechanical installation 71...
  • Page 72 72 Mechanical installation Declaration of Conformity Supply of Machinery (Safety) Regulations 2008 Manufacturer: ABB Oy Address: Hiomotie 13, 00380 Helsinki, Finland. Phone: +358 10 22 11 declare under our sole responsibility that the following products: Lifting bars, identified with material codes...
  • Page 73 Supply of Machinery (Safety) Regulations 2008. Authorized to compile the technical file: ABB Oy, Hiomotie 13, 00380 Helsinki, Finland Helsinki, 28 May 2021 Signed for and on behalf of:...

  • Page 75: Electrical Planning

    Limitation of liability The installation must always be designed and made according to applicable local laws and regulations. ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations. Furthermore, if the recommendations given by ABB are not followed, the drive may experience problems that the warranty does not cover.
  • Page 76 Definitions ACS880-07CLC nominal apparent power (trafo) Transformer or generator nominal apparent power (trafo) Transformer or generator nominal short-circuit impedance Example: Drive type: ACS880-07CLC-1660A-7 → S = 1984 kVA Transformer nominal power is, for example, 2500 kVA 2500 kVA (trafo) >...

  • Page 77: Selecting The Main Supply Disconnecting Device

    Electrical planning 77 The diagram below shows the typical current THD at nominal current in relation to supply transformer impedance in a 6-pulse connection. Current THD Supply transformer reactance Selecting the main supply disconnecting device You must equip the drive with a main supply disconnecting device which meets the local safety regulations.

  • Page 78: Examining The Compatibility Of The Motor And Drive

    Examining the compatibility of the motor and drive Use asynchronous AC induction motors, permanent magnet synchronous motors, AC induction servomotors or ABB synchronous reluctance motors (SynRM motors) with the drive. Select the motor size and drive type from the rating table on basis of the AC line voltage and motor load.

  • Page 79: Requirements For Abb Motors, P

    Nominal AC line Requirement for voltage Motor insula- ABB d u /d t and common mode filters, insulated tion system N-end motor bearings < 100 kW and frame size < IEC 315 < 134 hp and frame size < NEMA 500 Random-wound ≤...

  • Page 80: Requirements For Abb Motors, P

    82). Motor type Nominal AC line Requirement for voltage Motor insula- ABB d u /d t and common mode filters, insulated tion system N-end motor bearings 100 kW ≤ P < 350 kW ≥ 350 kW IEC 315 ≤ frame size <...

  • Page 81: Requirements For Non-Abb Motors, P

    Nominal AC line Requirement for voltage Motor insula- ABB d u /d t and common mode filters, insulated tion system N-end motor bearings < 100 kW and frame size < IEC 315 < 134 hp and frame size < NEMA 500 Random-wound and ≤...

  • Page 82: Requirements For Non-Abb Motors, P

    82). Motor type Nominal AC line Requirement for voltage Motor insula- ABB d u /d t and common mode filters, insulated tion system N-end motor bearings 100 kW ≤ P < 350 kW ≥ 350 kW IEC 315 ≤ frame size <...

  • Page 83: Availability Of D U /D T Filter And Common Mode Filter By Drive Type

    The rated output power of high-output motors is higher than what is stated for the particular frame size in EN 50347 (2001). If you plan to use a non-ABB high-output motor or an IP23 motor, consider these additional requirements for protecting the motor insulation and bearings in drive...

  • Page 84: Additional Data For Calculating The Rise Time And The Peak Line-To-Line Voltage

    If motor power is above 350 kW: Consult the motor manufacturer. Nominal AC supply Requirement for voltage Motor insulation system ABB d u /d t and common mode filters, insulated N- end motor bearings 100 kW < P < 100 kW or frame size < 350 kW or <...

  • Page 85: Additional Note For Sine Filters

    Electrical planning 85 Drive with du/dt filter Û du/dt ------------ - (1/ s) l (m) Motor cable length Û Relative peak line-to-line voltage (d u /d t )/ U Relative voltage rate of change Note: Û value is approximately 20% higher during resistor braking. Note: Due to installation, cable types and motor impedance, the worst case value may be higher than the estimate value (curve).

  • Page 86: General Guidelines

    Make sure that the cable can enter the cabinet through the cable entry plate. Refer to the dimension drawings of the drive delivery or technical data in the drive hardware manual. For special cable entry solutions, consult ABB. Make sure that there is sufficient space to install the cable(s) and cable lugs to the terminals.

  • Page 87: Alternate Power Cable Types

    Electrical planning 87 Cable type Use as input power cabling Use as motor cabling and as brake resistor cabling Symmetrical shielded (or ar- mored) cable with three phase conductors and symmetrically constructed PE conductor and a shield (or armor) Symmetrical shielded (or ar- mored) cable with three phase conductors and a shield (or ar- mor), and separate PE conduct-...

  • Page 88: Not Allowed Power Cable Types

    88 Electrical planning Cable type Use as input power cabling Use as motor cabling and as brake resistor cabling WARNING! A single-core cable system: three If you use unshielded single- phase conductors and PE conduct- core cables in an IT network, or on cable tray make sure that the non- conductive outer sheath...

  • Page 89: Grounding Requirements

    Electrical planning 89 Insulation jacket Helix of copper tape or copper wire Copper wire shield Inner insulation Cable core Grounding requirements This section gives general requirements for grounding the drive. When you plan the grounding of the drive, obey all the applicable national and local regulations. The conductivity of the protective earth conductor(s) must be sufficient.

  • Page 90: Additional Grounding Requirements - Iec

    ￭ Only use shielded control cables. Use a double-shielded twisted pair cable for analog signals. ABB recommends this type of cable also for the pulse encoder signals. Use one individually shielded pair for each signal. Do not use common return for different analog signals.

  • Page 91: Signals In Separate Cables

    Relay cable ￭ The cable type with braided metallic shield (for example ÖLFLEX by LAPPKABEL, Germany) has been tested and approved by ABB. Control panel to drive cable ￭ Use EIA-485, Cat 5e (or better) cable with male RJ-45 connectors. The maximum length of the cable is 100 m (328 ft).

  • Page 92: The Motor Cable

    92 Electrical planning The following figure illustrates the cable routing guidelines with an example drive. min. 300 mm (12 in) min. 300 mm (12 in) min. 500 mm (20 in) 90° min. 200 mm (8 in) min. 500 mm (20 in) Motor cable Input power cable Control cable...

  • Page 93: Roxtec Cable Entry (Option +H394)

    Roxtec cable entry (option +H394) The cabinet can be equipped with a multi-cable transit frame for Roxtec cable entry (option +H394). ABB provides only the frames, not the seals or the installation tools. For sealing components and installation instructions, refer to www.roxtec.com.

  • Page 94: Situations And Against Thermal Overload

    The drive protects the motor cable and motor in a short-circuit situation when: • the motor cable is sized correctly • the motor cable type complies with the motor cable selection guidelines by ABB • the cable length does not exceed the allowed maximum length specified for the drive •...

  • Page 95: Protecting The Motor Against Overload Without Thermal Model Or Temperature Sensors

    Electrical planning 95 Protecting the motor against overload without thermal model or ￭ temperature sensors Motor overload protection protects the motor against overload without using motor thermal model or temperature sensors. Motor overload protection is required and specified by multiple standards including the US National Electric Code (NEC) and the common UL/IEC 61800-5-1 standard in conjunction with UL/IEC 60947-4-1.

  • Page 96: Implementing The Power Loss Ride-Through Function

    IEC/EN/UL 61800-5-1, subclause 6.5.3, for example, “THIS MACHINE STARTS AUTOMATICALLY”. Bypass connection is available as a factory-installed option for some cabinet-installed drive types. Consult ABB for more information. WARNING! Never connect the drive output to the electrical power network. The connection may damage the drive.

  • Page 97: Using Power Factor Compensation Capacitors With The Drive

    Using a safety switch between the drive and the motor ABB recommends to install a safety switch between the permanent magnet motor and the drive output. The switch is needed to isolate the motor from the drive during maintenance work on the drive.

  • Page 98: Protecting The Contacts Of Relay Outputs

    98 Electrical planning When you select the DTC motor control mode and the motor coast stop mode, you can open the contactor immediately after the drive has received the stop command. This is the case also if you use the scalar motor control mode. Protecting the contacts of relay outputs Inductive loads (relays, contactors, motors) cause voltage transients when switched off.

  • Page 99: Connecting A Motor Temperature Sensor To The Drive Through An Option Module

    Electrical planning 99 If there is double or reinforced insulation between the sensor and the live parts of the motor: You can connect the sensor directly to the analog/digital input(s) of the drive. See the control cable connection instructions. Make sure that the voltage is not more than the maximum allowed voltage over the sensor.
  • Page 100 100 Electrical planning Option module Temperature sensor type Temperature sensor in- sulation requirement Type Insulation/Isolation Pt100, Pt1000 FEN-21 Galvanic isolation between sensor Reinforced insulation connector and drive control unit connector. No isolation between sensor connector and TTL encoder emulation output. FEN-31 Galvanic isolation between sensor Reinforced insulation...

  • Page 101: Electrical Installation

    Use a measuring voltage of 1000 V DC. The insulation resistance of an ABB motor must be more than 100 Mohm (reference value at 25 °C [77 °F]). For the insulation resistance of other motors, refer to the manufacturer’s...

  • Page 102: Measuring The Insulation Resistance Of The Input Power Cable

    102 Electrical installation Note: Moisture inside the motor reduces the insulation resistance. If you think that there is moisture in the motor, dry the motor and do the measurement again. U1-PE, V1-PE, W1-PE 1000 V DC, > 100 Mohm Measuring the insulation resistance of the input power cable ￭...

  • Page 103: Connecting The Motor Cables (Units Without Common Motor Terminal Cubicle)

    Electrical installation 103 Connecting the motor cables (units without common motor terminal cubicle) On units without a common motor terminal cubicle, the motor cables connect to busbars located in the inverter module cubicles. To access the terminals, the cooling fans and other equipment in front of the terminals must be removed from the cubicle. The location and dimensions of the busbars are visible in the dimension drawings delivered with the drive, and in the dimension drawing examples shown in this manual.

  • Page 104: Motor Connection Diagram (With Option +H366)

    104 Electrical installation Motor connection diagram (with option +H366) ￭ With option +H366, the output busbars of the inverter modules within the same cubicle are connected by bridging busbars. The bridging balances the motor current between the modules, which allows more cabling options. For example, it is possible to use a number of cables that could not otherwise be evenly distributed between the inverter modules.

  • Page 105: Procedure

    Electrical installation 105 Procedure ￭ Removing the shrouds WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. The illustration below shows the parts to be removed. Inner shroud Fan retaining screws Lower front mounting plate...
  • Page 106 106 Electrical installation IP54 cabinet: Remove the rear horizontal cable support bracket and the cable entry plate. IP54 cabinet: Remove a sealing grommet from the cable entry plate for each cable. Cut hole into the rubber grommet and move it onto the cable. Put the cables inside the cabinet through the cable entry plate.

  • Page 107: Installing The Fans And Shrouds

    Electrical installation 107 WARNING! Do not tighten the clamp on the bare shield (stripped part of the cable). It can damage the cable. For each cable, connect the PE conductor to the PE busbar, and two phase conductors to the phase terminals. Connect the third phase conductor to the PE busbar.

  • Page 108: At The Motor End

    108 Electrical installation Install the lower front mounting plate. Connect the wiring to the components on the mounting plate. Install the outer shroud. Make sure there are no tools, debris or any other foreign objects in the cubicle. Close the cubicle door. At the motor end At the motor, connect the cables according to instructions from the motor manufacturer.

  • Page 109: Connecting The Motor Cables (Units With Common Motor Terminal Cubicle)

    Electrical installation 109 Connecting the motor cables (units with common motor terminal cubicle) Output busbars ￭ If the drive is equipped with option +H359, the motor cables connect to a common motor terminal cubicle. The location and dimensions of the busbars are visible in the dimensional drawings delivered with the drive.

  • Page 110: Connecting The Cables

    110 Electrical installation Connecting the cables Do the steps in section Electrical safety precautions (page 19) before you start the work. Lead the cables into the cubicle. Make the 360° grounding arrangement at the cable entry as shown. Cut the cables to suitable length. Strip the cables and conductors. Twist the cable screens into bundles and connect the bundles to the PE busbar in the cubicle.

  • Page 111: Installing Shrouds

    Electrical installation 111 Connect the phase conductors to the output terminals. Use the tightening torques specified in section Tightening torques (page 225). At the motor, connect the cables according to instructions from the motor manufacturer. Pay special attention to the phase order. For minimum radio-frequency interference, ground the cable shield 360°...

  • Page 112: Connecting The Input Power Cables

    112 Electrical installation Connecting the input power cables Connection diagrams ￭ The connection diagrams below show the input power connections as well as the external equipment required. The diagrams are simplified. The designer of the drive system must provide the final, detailed circuit diagrams to the installer. Connection diagram –...

  • Page 113: Connection Diagram - 2×D8D, 12-Pulse, Internal Charging

    Electrical installation 113 Connection diagram – 2×D8D, 12-pulse, internal charging External installation outside drive cabinet Supply unit cubicle of drive Medium voltage/low voltage switchboard DC link Supply transformer Supply modules Charging switchgear including: Charging circuit (option +F272) • Disconnecting device Interlocked dedicated supply unit switchgear AC fuses including:...

  • Page 114: Connection Diagram - 2×D8D, 6-Pulse, External Charging And Pre-Magnetizing

    114 Electrical installation Connection diagram – 2×D8D, 6-pulse, external charging and pre-magnetizing External installation outside drive cabinet Supply unit cubicle of drive Medium voltage/low voltage switchboard DC link Switchgear including: Supply modules • Disconnecting device • Breaker/contactor Combined transformer pre-magnetizing cir- AC fuses cuit and drive charging circuit Supply transformer...

  • Page 115: Connection Diagram - 2×D8D, 12-Pulse, External Charging And Pre-Magnetizing

    Electrical installation 115 Connection diagram – 2×D8D, 12-pulse, external charging and pre-magnetizing External installation outside drive cabinet Supply unit cubicle of drive Medium voltage/low voltage switchboard DC link Switchgear including: Supply modules • Disconnecting device • Breaker/contactor Combined transformer pre-magnetizing cir- AC fuses cuit and drive charging circuit Supply transformer...

  • Page 116: Connection Procedure

    116 Electrical installation Connection procedure ￭ WARNING! Do the steps in section Electrical safety precautions (page 19) before you start the work. Removing shrouds Open the door of the incoming cubicle. Remove the shrouding and assembly plates covering the input terminals. Connecting the cables This section describes the power cable connecting procedure for a bottom cable entry with the standard cable entry plate.
  • Page 117 Electrical installation 117 IP54 cabinet: Remove the rear horizontal cable support bracket and the cable entry plate. IP54 cabinet: Remove a sealing grommet from the cable entry plate for each cable. Cut hole into the rubber grommet and move it onto the cable. Put the cables inside the cabinet through the cable entry plate.

  • Page 118: Installing Shrouds

    118 Electrical installation WARNING! Do not tighten the clamp on the bare shield (stripped part of the cable). It can damage the cable. For each cable, connect the PE conductor to the PE busbar, and two phase conductors to the phase terminals. Connect the third phase conductor to the PE busbar.

  • Page 119: Use Of Fasteners In Cable Lug Connections

    Electrical installation 119 Use of fasteners in cable lug connections Use the bolts, nuts and washers delivered with the drive. Install all the fasteners in the correct order. See the figure below. Tighten the cable lug to the torque specified for the connection.

  • Page 120: Connecting The Control Cables

    120 Electrical installation Connecting the control cables The default I/O connections can be different with some hardware options. See the circuit diagrams delivered with the drive for the actual wiring. For other control programs, see their firmware manuals. WARNING! The alarm indication connections of optional ground fault monitoring (+Q954) at terminal block X22.2 are decisive voltage class DVC-C.
  • Page 121 Electrical installation 121 If the outer surface of the shield is non-conductive: • Cut the shield at the midpoint of the peeled part. Be careful not to cut the conductors or the grounding wire. • Turn the conductive side of the shield inside out over the insulation. •...

  • Page 122: Routing The Control Cables Inside The Cabinet

    122 Electrical installation Routing the control cables inside the cabinet Use the existing trunking in the cabinet where possible. Use sleeving if cables are laid against sharp edges. When running cables to or from a swing-out frame, leave enough slack at the hinge to allow the frame to open fully. Connecting control cabling Connect the conductors to the appropriate terminals.
  • Page 123 Electrical installation 123 The drawing below represents the grounding of the control cabling when connecting to a terminal block inside the cabinet. The grounding is done in the same way when connecting directly to a component such as the control unit.

  • Page 124: Connecting A Pc

    124 Electrical installation Connecting a PC WARNING! Do not connect the PC directly to the control panel connector of the control unit. It can cause damage. A PC (with, for example, the Drive Composer PC tool) can be connected as follows: To connect a control panel to the unit, either •...

  • Page 125: Panel Bus (Control Of Several Units From One Control Panel)

    Electrical installation 125 Panel bus (control of several units from one control panel) One control panel (or PC) can be used to control several drives (or inverter units, supply units etc.) by constructing a panel bus. This is done by daisy-chaining the panel connections of the drives.
  • Page 126 126 Electrical installation With twin connectors in the control panel holder:...

  • Page 127: Installing Option Modules

    Electrical installation 127 With FDPI-02 modules and BCU control unit: Installing option modules Installing option modules (UCU) ￭ A slot adapter is necessary if you install F-series option modules onto the control unit. You can install a maximum of 3 slot adapters per control unit.
  • Page 128 128 Electrical installation WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work. Stop the drive and do the steps in section Electrical safety precautions (page 19) before you start the work.

  • Page 129: Mechanical Installation Of I/O Extension, Fieldbus Adapter And Pulse Encoder

    Electrical installation 129 Mechanical installation of I/O extension, fieldbus adapter and pulse ￭ encoder interface modules on BCU WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work.
  • Page 130 130 Electrical installation If you must remove the option module after it is installed into the drive, use a suitable tool (for example, small pliers) to carefully pull out the lock.

  • Page 131: Installation Of An Fso Safety Functions Module Onto Bcu Control Unit

    Electrical installation 131 Installation of an FSO safety functions module onto BCU control unit ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work.

  • Page 132: Wiring Of Option Modules

    132 Electrical installation Wiring of option modules ￭ See the applicable optional module manual for specific installation and wiring instructions.

  • Page 133: Control Unit (Ucu)

    14 power module connections. The UCU control units have integrated branching unit functionality for collecting and storing real-time data from the power modules to help fault tracing and analysis. The data is stored on a memory card which can be analyzed by ABB service personnel.

  • Page 134: Layout

    134 Control unit (UCU) Layout The figures below show an example UCU-24 control unit. Description I/O terminals SLOT 1 I/O extension, encoder interface or fieldbus SLOT 2 adapter module connection. For F-type modules with USCA-02 adapter. SLOT 3 SLOT 4 RDCO-0x DDCS communication option module connection UMU-01 memory unit connection.
  • Page 135 Control unit (UCU) 135 Description Analog input Analog output XCAN Not in use XCAN TERM CAN bus termination switch Digital input XDIO Digital input/output XD2D Drive-to-drive link XD24 +24 V output (for digital input) XETH1 Ethernet ports for fieldbus, internal switch XETH2 XETH3 Ethernet ports for tool communication, internal...
  • Page 136 136 Control unit (UCU) Description XFSO Not in use Humidity and temperature measurements XFSO...

  • Page 137: Default I/O Diagram Of The Inverter Control Unit

    Control unit (UCU) 137 Default I/O diagram of the inverter control unit This diagram shows the default control connections of the inverter control unit or the drive control unit. The ACS880 primary control program is in use. Under normal circumstances, the factory-made wiring should not be changed. Terminal Description XD2D...
  • Page 138 138 Control unit (UCU) Terminal Description Norm. closed XRO4: Not supported COM4 Common 250 V AC / 30 V DC, 2 A Norm. open XSTO Safe torque off input connection XSTO: STO1 and STO2 are connected to OUT at the factory. To enable start SGND and operation, STO1 and STO2 must be connected to OUT.
  • Page 139 Control unit (UCU) 139 Terminal Description Analog outputs Motor speed rpm 0 … 20 mA, R < 500 ohm AGND Motor current 0 … 20 mA, R < 500 ohm AGND XPOW External power input +24VI 19…32 V DC, 1.5…2.9 A (depends on the load and supply voltage) External power input +24VI Two supplies can be connected to the control unit for redundancy.
  • Page 140 140 Control unit (UCU) This is an I/O connection example for the inverter control unit. XRO1…XRO4 COM1 COM2 COM3 COM4 XSTO SGND STO1 STO2 DIIL XD24 +24VD +24VD AI1+ AI1- AI2+ AI2- AGND AGND Fault Connected at the factory. If necessary, you can connect a safety device (eg, a safety relay) to the XSTO terminal.

  • Page 141: Additional Information On The Connections

    Control unit (UCU) 141 Additional information on the connections Connecting motor temperature sensors to the drive ￭ Refer to the electrical planning instructions. Power supply for the control unit (XPOW) ￭ Power to the control unit is supplied internally through terminal block XPOW. Refer to the control unit connector data for the current and voltage ratings of the power supply.

  • Page 142: Safe Torque Off (Xsto, Xsto Out)

    The data is stored onto the microSDHC memory card inserted into the UMU-01 memory unit and can be analyzed by ABB service personnel. Connector data The wire size accepted by all screw terminals (for both stranded and solid wire) is 0.5 …...
  • Page 143 Control unit (UCU) 143 Digital inputs DI1…DI6 24 V logic levels: “0” < 5 V, “1” > 15 V (XDI:1…XDI:6) : 2.0 kohm Input type: NPN/PNP (DI1…DI5), PNP (DI6) Hardware filtering: 0.04 ms, digital filtering up to 8 ms : 15 mA (DI1…DI5), 5 mA (DI6) Start interlock input DIIL (XDI:7) 24 V logic levels: "0"...
  • Page 144 144 Control unit (UCU) Safe torque off connection (XSTO) Input voltage range: -3…30 V DC Logic levels: "0" < 5 V, "1" > 17 V. Note: Both circuits must be closed to enable start and operation (STO1 and STO2 must be connected to OUT). This applies to all control units (including drive, inverter, supply, brake, DC/DC converter etc.

  • Page 145: Ground Isolation Diagram

    Control unit (UCU) 145 Ground isolation diagram ￭ XPOW XD2D X485 XCAN XETH1 XETH2 XETH3 XETH4 XPAN XRO1-XRO4 COM1 … COM4 XD24 +24VD DICOM +24VD DIOGND XDIO DIO1 DIO2 DIOGND DIOGND DIIL XSTO XSTO OUT Power supply ground *The maximum common mode voltage between each AI input and AGND is ±30 V. **Ground selector (DICOM=DIOGND) settings DICOM=DIOGND: ON All digital inputs share a common ground (DICOM connected to DIOGND).

  • Page 147: Control Units (Bcu And Zcu)

    Control units (BCU and ZCU) 147 Control units (BCU and ZCU) Contents of this chapter This chapter • describes the connections of the control unit(s) used in the drive, • contains the specifications of the inputs and outputs of the control unit(s). General The supply unit of the drive is controlled by a dedicated ZCU-14 control unit (component designation A51).

  • Page 148: Zcu-14 Layout

    148 Control units (BCU and ZCU) ZCU-14 ZCU-14 layout ￭ Description XPOW External power input Analog inputs XRO1 Analog outputs XD2D Drive-to-drive link XRO2 XRO1 Relay output RO1 XRO2 Relay output RO2 XRO3 Relay output RO3 XRO3 XD24 Digital input interlock (DIIL) and +24 V output XPOW XDIO...

  • Page 149: Zcu-14 Default I/O Connection Diagram

    Control units (BCU and ZCU) 149 ZCU-14 default I/O connection diagram ￭ The diagram shows the control connections of the supply unit, and the default meaning or use of the signals in the supply unit control program. Relay outputs XRO1…XRO3 XRO1: Charging (Charging contactor control) 250 V AC / 30 V DC XRO2: Fault(-1) / Started...
  • Page 150 150 Control units (BCU and ZCU) Note: Wire sizes and tightening torques: 0.5…2.5 mm (24…12 AWG) and 0.5 N·m (5 lbf·in) for both stranded and solid wire. Started (Cooling unit control) if the drive is equipped with optional cooling unit. Current [0(4)…20 mA, R = 100 ohm] or voltage [0(2)…10 V, R >...

  • Page 151: Bcu

    Control units (BCU and ZCU) 151 Layout ￭ Description I/O terminals (see following diagram) SLOT 1 I/O extension, encoder interface or fieldbus adapter module connection. (This is the sole location for an FDPI-02 diagnostics and panel interface.) SLOT 2 I/O extension, encoder interface or fieldbus adapter module connection SLOT 3 I/O extension, encoder interface or...
  • Page 152 152 Control units (BCU and ZCU) Description Analog inputs Analog outputs Digital inputs, Digital input interlock (DIIL) XRO3 XD24 XPOW XDIO Digital input/outputs XD2D Drive-to-drive link XRO2 XD24 +24 V output (for digital inputs) XDIO XETH Ethernet port – Not in use XPOW External power input XRO1...

  • Page 153: Default I/O Diagram Of The Inverter Control Unit (Bcu)

    Control units (BCU and ZCU) 153 Default I/O diagram of the inverter control unit (BCU) ￭ This diagram shows the default control connections of the inverter control unit or the drive control unit. The ACS880 primary control program is in use .
  • Page 154 154 Control units (BCU and ZCU) Terminal Description Stop (0) / Start (1) Forward (0) / Reverse (1) Reset Acceleration & deceleration select Constant speed 1 select (1 = on) Not in use by default. DIIL Run enable. DIIL is connected to XD24:5 at the factory. XDIO Digital input/outputs DIO1...
  • Page 155 Control units (BCU and ZCU) 155 Terminal Description X205 Memory unit connection 1) 0 = Acceleration/deceleration ramps defined by parameters 23.12/23.13 in use. 1 = Acceleration/deceleration ramps defined by parameters 23.14/23.15 in use. 2) Constant speed 1 is defined by parameter 22.26. 3) The DIIL input is configured to stop the unit when the input signal is removed.
  • Page 156 156 Control units (BCU and ZCU) The diagram below shows an I/O connection example for the inverter control unit (A41). XRO1…XRO3 XSTO SGND DIIL XD24 +24VD +24VD AI1+ AI1- AI2+ AI2- AGND AGND Fault Connected at the factory. If necessary, you can connect a safety device (for example, a safety relay) to the XSTO terminal.

  • Page 157: Bcu, Zcu-14 Connections Additional Info

    Note: This input is not SIL or PL classified. The XD2D connector Note: On the ACS880-07CLC, the XD2D connector on the supply control unit (A51) is reserved for cooling fan monitoring. Refer to CIO-01 I/O module for distributed I/O bus control user's manual (3AXD50000126880 [English]).

  • Page 158: Safe Torque Off (Xsto, Xsto Out)

    The control unit has an on-board data logger that collects real-time data from the power modules to help fault tracing and analysis. The data is stored onto the SDHC memory card inserted into the SD CARD slot and can be analyzed by ABB service personnel.
  • Page 159 Control units (BCU and ZCU) 159 Relay outputs RO1…RO3 250 V AC / 30 V DC, 2 A (XRO1…XRO3) Protected by varistors +24 V output (XD24:5 and XD24:7) Total load capacity of these outputs is 4.8 W (200 mA / 24 V) minus the power taken by DIO1 and DIO2.
  • Page 160 160 Control units (BCU and ZCU) Safe torque off connection (XSTO) Input voltage range: -3…30 V DC Logic levels: "0" < 5 V, "1" > 17 V. Note: Both circuits must be closed to enable start and operation (IN1 and IN2 must be connected to OUT). This applies to all control units (including drive, inverter, supply, brake, DC/DC converter etc.

  • Page 161: Bcu Ground Isolation Diagram

    Control units (BCU and ZCU) 161 BCU ground isolation diagram XPOW +24VI +24VI +VREF -VREF AGND AI1+ AI1- AI2+ AI2- AGND AGND XD2D BGND SHIELD XRO1, XRO2, XRO3 XD24 +24VD DICOM +24VD DIOGND XDIO DIO1 DIO2 DIOGND DIOGND DIIL XSTO SGND XSTO OUT SGND...

  • Page 162: Zcu Ground Isolation Diagram

    162 Control units (BCU and ZCU) ZCU ground isolation diagram XPOW +24VI +VREF -VREF AGND AI1+ Common mode voltage between AI1- AI2+ channels ±30 V AI2- AGND AGND XD2D BGND XRO1, XRO2, XRO3 XD24 DIIL +24VD DICOM +24VD DIOGND XDIO DIO1 DIO2 XSTO...

  • Page 163: Installation Checklist

    Installation checklist 163 Installation checklist Contents of this chapter This chapter contains a checklist for the mechanical and electrical installation of the drive. Checklist Examine the mechanical and electrical installation of the drive before start-up. Go through the checklist together with another person. WARNING! Obey the safety instructions of the drive.
  • Page 164 164 Installation checklist Make sure that … If the drive is connected to a network other than a symmetrically grounded TN-S system: You have done all the required modifications (for example, you may need to disconnect the EMC filter or ground-to-phase varistor) the electrical installation instructions. There is an adequately sized protective earth (ground) conductor(s) between the drive and the switchboard, the conductor is connected to correct terminal, and the terminal is tightened to the correct torque.

  • Page 165: Start-Up

    Start-up 165 Start-up Contents of this chapter This chapter contains the start-up and switch-off procedures of the drive. Start-up procedure The tasks which are needed in certain cases only are marked with underlining, and option codes are given in brackets. Default device designations (if any) are given in brackets after the name, for example “main switch-disconnector [Q1]”.
  • Page 166 166 Start-up Action Checks/Settings with no voltage connected Make sure that the disconnector of the supply transformer is locked to the open position (i.e., voltage is not connected to the drive, and cannot be connected to the drive accidentally). Make sure that the main switch-disconnector is open, or the main breaker is racked out. Both are external customer equipment.

  • Page 167: Switching Off The Drive

    Start-up 167 Action Drives with an encoder interface module (optional): Set the encoder parameters. Activate the appropriate assistant (if present) in the control program, or see the user’s manual of the encoder interface module, and the drive firmware manual. Powering up the main circuit of the drive Set the Run enable switch into the "1"...

  • Page 169: Maintenance

    Contents of this chapter This chapter contains maintenance instructions. Maintenance intervals The tables show the maintenance tasks that can be done by the end user. For the ABB Service offering, contact your local ABB Service representative (new.abb.com/contact-centers). Description of symbols ￭...
  • Page 170 • The maintenance and component replacement intervals are based on the assumption that the equipment operates within the specified ratings and ambient conditions. ABB recommends annual drive inspections to ensure the highest reliability and optimum performance. • Long-term operation near the specified maximum ratings or ambient conditions may require shorter maintenance intervals for certain components.

  • Page 171: Cooling Fans

    Reset the running time signal after fan replacement. Replacement fans are available from ABB. Do not use other than ABB specified spare parts. Replacing the cooling fan in the supply module cubicle ￭...

  • Page 172: Replacing The Cooling Fan Of An Inverter Module

    172 Maintenance Replacing the cooling fan of an inverter module ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work.

  • Page 173: Replacing The Common Motor Terminal Cubicle Fan

    Maintenance 173 Replacing the common motor terminal cubicle fan ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work. WARNING! Use the required personal protective equipment.

  • Page 174: Fuses

    174 Maintenance Fuses Replacing the AC fuses ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work. WARNING! Use the required personal protective equipment.

  • Page 175: Replacing The Dc Fuses

    Maintenance 175 Replacing the DC fuses ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work. WARNING! Use the required personal protective equipment.
  • Page 176 176 Maintenance...

  • Page 177: Supply And Inverter Modules

    The module is heavy. Reserve two persons, hoist and a suitable platform for the replacement procedure. Keep the module fastened to the hoist to prevent the module from falling. For information on a lifting device available from ABB, refer to...
  • Page 178 178 Maintenance 11. Slacken the nuts of the AC fuse blocks and slide the fuses out. 12. Remove the DC bus screws. 13. Remove the four mounting screws of the module and lift the module out. 14. If you need to remove the module in the rear, remove the shroud between the front and rear modules.
  • Page 179 Maintenance 179...
  • Page 180 180 Maintenance...

  • Page 181: Replacing An Inverter Module

    The module is heavy. Reserve two persons, hoist and a suitable platform for the replacement procedure. Keep the module fastened to the hoist to prevent the module from falling. For information on a lifting device available from ABB, refer to...

  • Page 182: Removing The Module

    (page 181). Install the converter module lifting device by ABB, or make sure that you have another winch in use. For information on a lifting device available from ABB, refer Converter module lifting device for drive cabinets hardware manual (3AXD50000210268 [English]).
  • Page 183 Maintenance 183 Remove the L-shaped DC busbars at the top of the module. Make note of the orientation of the screws as well as the order of the washers. Close the inlet valve (a) and outlet valve (located on the right-hand side of the cubicle).
  • Page 184 184 Maintenance After the module has drained, disconnect the piping from the module. 10. Remove the module retaining screws at the top and the bottom of the module.

  • Page 185: Installing The Module

    Assembling the service platform (page 181). Install the converter module lifting device by ABB, or make sure that you have another winch in use. For information on a lifting device available from ABB, refer Converter module lifting device for drive cabinets hardware manual (3AXD50000210268 [English]).

  • Page 186: Activating The Reduced Run Of The Inverter Unit

    Note: The wiring accessories and the air baffle needed during the procedure are included in the delivery, and separately available from ABB. WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur.

  • Page 187: Installing The Module

    Maintenance 187 If the Safe torque off (STO) function is in use, install the jumper wire set included in the STO wiring in place of the missing module. (This is not needed if the module was the last on the STO wire chain.) Removed module Jumper wire set (R8i)

  • Page 188: Capacitors

    Capacitor failure is usually followed by damage to the unit and an input cable fuse failure, or a fault trip. If you think that any capacitors in the drive have failed, contact ABB. Reforming the capacitors ￭ The capacitors must be reformed if the drive has not been powered (either in storage or unused) for a year or more.

  • Page 189: Control Units

    Maintenance 189 Control units UCU control unit ￭ Replacing the memory unit of the UCU control unit If you replace the control unit, move the memory unit from the old control unit to the new control unit to keep the existing parameter settings. WARNING! Obey the safety instructions of the drive.

  • Page 190: Replacing The Ucu Control Unit Battery

    190 Maintenance Replacing the UCU control unit battery WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work. Replace the real-time clock battery if the BAT LED is off when the control unit is powered.

  • Page 191: Replacing The Microsd/Microsdhc Memory Card Of Ucu Control Unit

    Maintenance 191 Replacing the microSD/microSDHC memory card of UCU control unit WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work.

  • Page 192: Bcu Control Unit

    192 Maintenance BCU control unit ￭ BCU control unit types There are three variants of the BCU control unit used in ACS880 drives: BCU-02, BCU-12 and BCU-22. These have a different number of converter module connections (2, 7 and 12 respectively) but are otherwise identical. The three BCU types are interchangeable as long as the number of connections is sufficient.

  • Page 193: Replacing The Bcu Control Unit Battery

    Maintenance 193 Replacing the BCU control unit battery WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work. Replace the real-time clock battery if the BATT OK LED is off when the control unit is powered.

  • Page 194: Functional Safety Components

    Note that some of the components may already have been renewed earlier, restarting their mission time. The remaining mission time of the whole circuit is however determined by its oldest component. Contact your local ABB service representative for more information.

  • Page 195: Technical Data

    The nominal ratings for the drives with 50 Hz and 60 Hz supply are given below. The definitions are described below the table. Input Output ratings rat- No-overload use Light-overload use Heavy-duty use ACS880-07CLC-… = 690 V, 6-pulse connection 0390A-7 0430A-7 0480A-7 0530A-7 0600A-7 0670A-7...
  • Page 196 196 Technical data Input Output ratings rat- No-overload use Light-overload use Heavy-duty use ACS880-07CLC-… 1940A-7 1775 1940 2910 1800 2000 2319 1862 1800 2000 1451 1400 1500 2180A-7 1995 2180 3270 2000 2605 2093 2000 1631 1400 1750 2470A-7 2261...

  • Page 197: Definitions

    Note 2: To achieve the rated motor power given in the table, the rated current of the drive must be higher than or equal to the rated motor current. The DriveSize dimensioning tool available from ABB is recommended for selecting the drive, motor and gear combination.

  • Page 198: Switching Frequency Derating

    Note that this concerns continuous or frequent use in this frequency range. Temporary use in frequency range below 12 Hz does not cause need for derating. Frame sizes and power module types Supply modules used Inverter modules used ACS880-07CLC-… Frame size Type Type = 690 V, 6-pulse connection...
  • Page 199 Technical data 199 Supply modules used Inverter modules used ACS880-07CLC-… Frame size Type Type ACS880-304LC-0820A- 1170A-7 2×D8D + 2×R8i ACS880-104LC-0600A-7 7+A019 ACS880-304LC-0820A- 1310A-7 2×D8D + 2×R8i ACS880-104LC-0670A-7 7+A019 ACS880-304LC-0820A- 1470A-7 2×D8D + 2×R8i ACS880-104LC-0750A-7 7+A019 ACS880-304LC-0820A- 1660A-7 2×D8D + 2×R8i...
  • Page 200 200 Technical data Supply modules used Inverter modules used ACS880-07CLC-… Frame size Type Type ACS880-304LC-0820A- 3580A-7+A004 6×D8D + 5×R8i ACS880-104LC-0750A-7 7+A019 ACS880-304LC-0820A- 4050A-7+A004 6×D8D + 5×R8i ACS880-104LC-0850A-7 7+A019 ACS880-304LC-0820A- 4840A-7+A004 6×D8D + 6×R8i ACS880-104LC-0850A-7 7+A019 ACS880-304LC-0820A- 5650A-7+A004 8×D8D + 7×R8i...

  • Page 201: Fuses

    Fuses from other manufacturers can be used if they meet the ratings and the melting curve of the fuse does not exceed the melting curve of the fuse mentioned in the table. Ultrarapid (aR) fuses at supply module input ACS880-07CLC-… s at Manufacturer Type...
  • Page 202 202 Technical data DC fuses at inverter module input ACS880-07CLC-… Manufacturer Type 0530A-7 1000 1100 Bussmann 170M6548 0600A-7 1100 1000 Bussmann 170M6549 0670A-7 1250 1100 Bussmann 170M6500 0750A-7 1400 1100 Bussmann 170M6501 0850A-7 1030A-7 1000 1100 Bussmann 170M6548 1170A-7 1100...

  • Page 203: Brake Chopper Dc Fuses

    Technical data 203 DC fuses at inverter module input ACS880-07CLC-… Manufacturer Type 2470A-7+A006 3260A-7+A006 4840A-7+A006 1400 1100 Bussmann 170M6501 5650A-7+A006 6460A-7+A006 Brake chopper DC fuses ￭ Optional (+D150) single-phase brake choppers have two DC fuses each. The fuse type is Bussmann 170M5146 (630 A 1250 V).
  • Page 204 204 Technical data Coolant flow Heat dissipation Noise ACS880-07CLC-… l/min US gal/min dB(A) 1940A-7 2180A-7 2470A-7 2880A-7 3260A-7 = 690 V, 12-pulse connection 0530A-7+A004 10.0 0600A-7+A004 10.0 0670A-7+A004 10.0 0750A-7+A004 10.0 0850A-7+A004 10.0 1030A-7+A004 14.3 1170A-7+A004 14.3 1310A-7+A004 14.3 1470A-7+A004 14.3...

  • Page 205: Input Cable Sizes

    30 °C (EN 60204-1 and IEC 60364-5-52). A correction factor K = 0.70 is used. Marine-type cable Industrial-type cable Aluminum with Aluminum with PVC Copper with PVC ACS880-07CLC-… Copper XLPE insulation insulation insulation = 690 V, 6-pulse connection 0390A-7 3 ×...
  • Page 206 206 Technical data Marine-type cable Industrial-type cable Aluminum with Aluminum with PVC Copper with PVC ACS880-07CLC-… Copper XLPE insulation insulation insulation 2 × 2 × (3 × 95 + 29 2 × 2 × (3 × 150 + 41 0670A-7+A004 2 ×...

  • Page 207: Output Cable Sizes

    30 °C (EN 60204-1 and IEC 60364-5-52). A correction factor K = 0.70 is used. Marine-type cable Industrial-type cable Aluminum with PVC insula- Copper with PVC insula- ACS880-07CLC-… Copper tion tion = 690 V, 6-pulse connection 0390A-7 3 ×...
  • Page 208 208 Technical data Marine-type cable Industrial-type cable Aluminum with PVC insula- Copper with PVC insula- ACS880-07CLC-… Copper tion tion 2180A-7+A004 3 × 4 × (3 × 120) 3 × 4 × (3 × 185 + 57 Cu) 3 × 3 × (3 × 185 + 95) 2470A-7+A004 3 ×...

  • Page 209: Terminal And Cable Entry Data For The Power Cables

    Technical data 209 Terminal and cable entry data for the power cables The locations and sizes of the cable entries are shown in the dimension drawings delivered with the drive, and the dimension drawing examples in this manual. Busbar terminal material: Tin-plated copper. Connection capability for input cables (frame D8D and multiples) ￭...

  • Page 210: Aluminum Cables

    210 Technical data 3×D8D (500 mm cubicle) 4×D8D (500 mm cubicle) Cable cross Cable lugs can be ... Cable lugs can be ... Max. number of Max. number of section phase phase in each on both in each hole on both sides conductors conductors hole...

  • Page 211: Connection Capability For Motor Cables (Frame R8I And Multiples)

    Technical data 211 Connection capability for motor cables (frame R8i and multiples) ￭ The maximum number of motor cables depends on the cable size, cable material, number of inverter modules and on the inverter unit cubicle width. Before you select motor cable sizes, check the inverter unit construction from the project-specific dimension drawings and use the tables below to determine the connection capability.

  • Page 212: Terminal Data For Block X504

    212 Technical data Output terminal dimensions, n×R8i Distance between adja- Distance between adja- Maximum distance Maximum cable lug dia- cent holes, horizontal cent holes, vertical between terminal sur- meter (including pos- faces sible shrink hose) 30.5* 1.2* 44.5 1.75 2.63 1.14 Side view Front view...

  • Page 213: Motor Connection Data

    , 3-phase symmetrical, U at the field weakening point Frequency ( f 0…500 Hz • For higher operational output frequencies, please contact your local ABB representative. • Operation outside the range of 12…150 Hz requires derating. See the de- rating information.

  • Page 214: Cooling Fan Supply

    214 Technical data Control voltage supply (230/115 V) Minimum short-circuit Cable size recommenda- Terminal Power re- current tion torque ACS880-07CLC-… quirement (Q20, ABB approx. 230 V 115 V 230 V 115 V OT40) N·m (lbf·in) 2880A-7 (+A004) 1490 3 × 2.5 / 2.5 3 ×...

  • Page 215: Charging Circuit Supply

    0.8 (7.1) 6460A-7+A006 Charging circuit supply ￭ Charging circuit supply (525…690 V) Minimum short-circuit Cable size recommenda- Terminal torque ACS880-07CLC-… current tion (Q3, ABB OS40) N·m (lbf·in) 0390A-7 0430A-7 0480A-7 0530A-7(+A004) 0600A-7(+A004) 0670A-7(+A004) 0750A-7(+A004) 0850A-7(+A004) 3 × 2.5 / 2.5 2.0 (18)

  • Page 216: Relay Contact Data For Control Of External Main Contactor/Breaker

    216 Technical data Relay contact data for control of external main contactor/breaker General ￭ The external main contactor or breaker is controlled by the drive through relay K3. The relay has one normally-open (NO) and one normally-closed (NC) contact. Emergency stop options add a relay (K640) to the drive. To trip the main breaker upon an emergency stop, one of the output switchover contacts of the relay must be wired to the undervoltage coil.

  • Page 217: Energy Efficiency Data (Ecodesign)

    The efficiency is not calculated according to the ecodesign standard IEC 61800-9-2. Energy efficiency data (ecodesign) Energy efficiency data according to IEC-61800-9-2 is available from https://ecodesign.drivesmotors.abb.com and from ACS880-07CLC drives energy efficiency data (EU ecodesign) supplement (3AXD50000788415 [English]). Protection classes Degrees of protection...

  • Page 218: Transportation

    2K12: Transportation Not allowed. container). without temperature and Wooden crate humidity control allowed. Special vehicle Vertical requirements: High-cube container. ABB recommends the use of container desiccant bags in sea transportation. Seaworthy package Road, air, sea (in 2K12: Transportation 2K14: container).

  • Page 219: Storage Conditions

    Storage conditions The table below specifies the storage conditions for the drive. Store the drive in its package. ABB recommends seaworthy package (option +P912) if the drive is in long-term storage. The storage conditions must also comply with the environmental...

  • Page 220: Manuals

    Substances of Concern In articles as such or in complex objects (Products) established under the Waste Framework Directive (2008/98/EC). For further information, contact your local ABB distributor or consult European Chemicals Agency's SCIP database to find out which SVHCs are used in the drive, and to find out where those components are located.

  • Page 221: Markings

    Electronic Information Products (EIP) symbol including an Environment Friendly Use Period (EFUP). Product is compliant with the People’s Republic of China Electronic Industry Standard (SJ/T 11364-2014) about hazardous substances. The EFUP is 20 years. China RoHS II Declaration of Conformity is available from https://library.abb.com.

  • Page 222: Emc Compliance (Iec/En 61800-3)

    222 Technical data RCM mark Product complies with Australian and New Zealand requirements specific to EMC, telecom- munications and electrical safety. For fulfilling the EMC requirements, see the additional in- formation concerning the drive EMC compliance (IEC/EN 61800-3). WEEE mark At the end of life the product should enter the recycling system at an appropriate collection point and not placed in the normal waste stream.

  • Page 223: Category C4

    Technical data 223 Category C4 ￭ The drive complies with the C4 category with these provisions: It is made sure that no excessive emission is propagated to neighboring low-voltage networks. In some cases, the natural suppression in transformers and cables is sufficient. If in doubt, a supply transformer with static screening between the primary and secondary windings can be used.
  • Page 224 The fuses are listed elsewhere in this chapter. • The drive provides motor overload protection. The protection is not enabled when the drive leaves the ABB factory. For enabling the protection, see the firmware manual. • The drive overvoltage category according to IEC 60664-1 is III, except for auxiliary power connections (fan, control, heating, lighting, cooling unit pump etc) which are of category II.

  • Page 225: Tightening Torques

    Technical data 225 Tightening torques Unless a tightening torque is specified in the text, the following torques can be used. Electrical connections ￭ Size Torque Strength class 0.5 N·m (4.4 lbf·in) 4.6...8.8 1 N·m (9 lbf·in) 4.6...8.8 4 N·m (35 lbf·in) 9 N·m (6.6 lbf·ft) 22 N·m (16 lbf·ft) 42 N·m (31 lbf·ft)

  • Page 226: Cyber Security Disclaimer

    ABB and its affiliates are not liable for damages and/or losses related to such security breaches, any unauthorized access, interference, intrusion, leakage and/or theft of data or information.

  • Page 227: Dimensions

    The table is followed by selected dimension drawing examples. The dimensions are in millimeters (for inches, divide by 25.4). The data given is preliminary. ABB reserves the right to modify the design at any time without notice. Consult ABB for up-to-date, drive-specific information.
  • Page 228 228 Dimensions Width Weight ACS880-07CLC-… 2180A-7 1230 1030 2270 2470A-7 1230 1030 2270 2880A-7 1530 1290 2845 3260A-7 1530 1290 2845 = 690 V, 12-pulse connection 0530A-7+A004 1235 0600A-7+A004 1235 0670A-7+A004 1235 0750A-7+A004 1235 0850A-7+A004 1235 1030A-7+A004 1565 1170A-7+A004 1565...

  • Page 229: Dimension Drawing Examples

    Dimensions 229 Dimension drawing examples ￭ Cabinet height and depth Side view, bottom cable exit Side view, marine construction (option +C121), bottom cable exit...
  • Page 230 230 Dimensions Side view, top cable exit with common motor Side view, top cable exit without common motor terminal cubicle terminal cubicle...

  • Page 231: Acs880-07Clc-0390A-7 +C121 (Marine Construction)

    Dimensions 231 ACS880-07CLC-0390A-7 +C121 (marine construction)

  • Page 232: Acs880-07Clc-1310A-7

    232 Dimensions ACS880-07CLC-1310A-7...

  • Page 233: Acs880-07Clc-2180A-7 +C121 (Marine Construction)

    Dimensions 233 ACS880-07CLC-2180A-7 +C121 (marine construction)

  • Page 234: Acs880-07Clc-3260A-7 +C121 (Marine Construction)

    234 Dimensions ACS880-07CLC-3260A-7 +C121 (marine construction)

  • Page 235: Location And Size Of Input Terminals

    Dimensions 235 Location and size of input terminals Drives with up to four supply modules have one supply module cubicle while drives with more modules have two. For the quantity of supply modules in each drive type, Frame sizes and power module types (page 198).

  • Page 236: 2×D8D

    236 Dimensions 2×D8D ￭...

  • Page 237: 3×D8D

    Dimensions 237 3×D8D ￭...

  • Page 238: 4×D8D

    238 Dimensions 4×D8D ￭...

  • Page 239: Location And Size Of Output Terminals

    Dimensions 239 Location and size of output terminals Units without common motor terminal cubicle ￭ Inverter module cubicle with one R8i module, bottom cable exit...

  • Page 240: Inverter Module Cubicle With Two R8I Modules, Bottom Cable Exit

    240 Dimensions Inverter module cubicle with two R8i modules, bottom cable exit...

  • Page 241: Inverter Module Cubicle With Three R8I Modules, Bottom Cable Exit

    Dimensions 241 Inverter module cubicle with three R8i modules, bottom cable exit...

  • Page 242: Brake Chopper Cubicle

    242 Dimensions Brake chopper cubicle...

  • Page 243: Units With Common Motor Terminal Cubicle (+H359)

    Dimensions 243 Units with common motor terminal cubicle (+H359) ￭ Note: The cubicles used with ACS880-07CLC are: • 300 mm with types up to -1170A-7 • 400 mm with types -1310A-7 to -2470A-7 • 500 mm with types -2880A-7 and -3260A-7 •...

  • Page 244: Cubicle Width 400 Mm, Bottom Cable Exit

    244 Dimensions Cubicle width 400 mm, bottom cable exit...

  • Page 245: Cubicle Width 600 Mm, Bottom Cable Exit

    Dimensions 245 Cubicle width 600 mm, bottom cable exit...

  • Page 247: The Safe Torque Off Function

    The Safe torque off function 247 The Safe torque off function Contents of this chapter This chapter describes the Safe torque off (STO) function of the drive and gives instructions for its use. Description WARNING! In case of parallel-connected drives or dual-winding motors, the STO must be activated on each drive to remove the torque from the motor.

  • Page 248: Chinery (Safety) Regulations

    248 The Safe torque off function Standard Name IEC 61000-6-7:2014 Electromagnetic compatibility (EMC) – Part 6-7: Generic standards – Immunity requirements for equipment intended to perform functions in a safety-related system (functional safety) in industrial locations IEC 61326-3-1:2017 Electrical equipment for measurement, control and laboratory use – EMC requirements –...

  • Page 249: Wiring

    The contacts of the switch or relay must open/close within 200 ms of each other. Cable types and lengths ￭ • ABB recommends double-shielded twisted-pair cable. • Maximum cable lengths: • 300 m (1000 ft) between activation switch [K] and drive control unit •...

  • Page 250: Dual-Channel Connection With Internal Power Supply (Ucu)

    250 The Safe torque off function Dual-channel connection with internal power supply (UCU) ￭ XSTO +24 V SGND STO1 STO2 XSTO OUT STO IN (X52) OUT1 24VDC CH1 SGND GND CH1 OUT2 24VDC CH2 SGND GND CH2 STO IN (X52) STO OUT (X51) 24VDC CH1 24VDC CH1...

  • Page 251: Dual-Channel Connection With Internal Power Supply (Bcu)

    The Safe torque off function 251 Dual-channel connection with internal power supply (BCU) ￭ XSTO +24 V SGND XSTO OUT STO IN (X52) 24VDC CH1 SGND GND CH1 24VDC CH2 SGND GND CH2 STO IN (X52) STO OUT (X51) 24VDC CH1 24VDC CH1 GND CH1 GND CH1...

  • Page 252: Single-Channel Connection Of Activation Switch (Ucu)

    252 The Safe torque off function Single-channel connection of activation switch (UCU) ￭ XSTO +24 V SGND STO1 STO2 Note: • Both STO inputs (STO1, STO2) must be connected to the activation switch. Otherwise, no SIL/PL classification is given. • Pay special attention to avoiding any potential failure modes for the wiring. For example, use shielded cable.

  • Page 253: Multiple Drives

    The Safe torque off function 253 Multiple drives ￭ Internal power supply (example, drives with UCU) XSTO +24 V SGND STO1 STO2 XSTO SGND STO1 STO2 XSTO SGND STO1 STO2 Drive Control unit Activation switch...

  • Page 254: Internal Power Supply (Example, Drives With Bcu)

    254 The Safe torque off function Internal power supply (example, drives with BCU) XSTO +24 V SGND XSTO SGND XSTO SGND Drive Control unit Activation switch...

  • Page 255: External Power Supply (Example, Drives With Ucu)

    The Safe torque off function 255 External power supply (example, drives with UCU) 24 V DC XSTO +24 V SGND STO1 STO2 XSTO SGND STO1 STO2 XSTO SGND STO1 STO2 Drive Control unit Activation switch...

  • Page 256: External Power Supply (Example, Drives With Bcu)

    256 The Safe torque off function External power supply (example, drives with BCU) 24 V DC – XSTO +24 V SGND XSTO SGND XSTO SGND Drive Control unit Activation switch...

  • Page 257: Operation Principle

    The Safe torque off function 257 Operation principle The Safe torque off activates (the activation switch is opened, or safety relay contacts open). The STO inputs of the drive control unit de-energize. The control unit cuts off the control voltage from the output IGBTs. The control program generates an indication as defined by parameter 31.22 (see the firmware manual of the drive).

  • Page 258: Start-Up Including Validation Test

    258 The Safe torque off function Start-up including validation test To ensure the safe operation of a safety function, validation is required. The final assembler of the machine must validate the function by performing a validation test. The test must be performed at initial start-up of the safety function after any changes related to the safety function (circuit boards, wiring, components, settings, replacement of inverter module, etc.)
  • Page 259 The Safe torque off function 259 Action Test the operation of the STO function when the motor is stopped. • Give a stop command for the drive (if running) and wait until the motor shaft is at a standstill. Make sure that the drive operates as follows: •...

  • Page 260: Use

    260 The Safe torque off function Open the activation switch, or activate the safety functionality that is wired to the STO connection. The STO inputs on the drive control unit de-energize, and the control unit cuts off the control voltage from the output IGBTs. The control program generates an indication as defined by parameter 31.22 (see the firmware manual of the drive).
  • Page 261 The Safe torque off function 261 danger or is not otherwise acceptable, stop the drive and machinery using the appropriate stop mode before activating the Safe torque off function. • The Safe torque off function overrides all other functions of the drive. •...

  • Page 262: Maintenance

    If any wiring or component change is needed after start-up, or the parameters are restored, do the test given in section Validation test procedure (page 258). Use only spare parts approved by ABB. Record all maintenance and proof test activities in the machine logbook. Competence ￭...

  • Page 263: Perfect Proof Test Procedure

    The Safe torque off function 263 Perfect proof test procedure ￭ Action WARNING! Obey the safety instructions. If you ignore them, injury or death, or damage to the equip- ment can occur. Test the operation of the STO function. If the motor is running, it will stop during the test. •...

  • Page 264: Fault Tracing

    See the firmware manual of the drive control program for the indications generated by the drive, and for details on directing fault and warning indications to an output on the control unit for external diagnostics. Any failures of the Safe torque off function must be reported to ABB.

  • Page 265: Safety Data

    The Safe torque off function 265 Safety data The safety data for the Safe torque off function is given below. Note: The safety data is calculated for redundant use, and applies only if both STO channels are used.
  • Page 266 266 The Safe torque off function...

  • Page 267: Terms And Abbreviations

    The Safe torque off function 267 • The STO is a type B safety component as defined in IEC 61508-2. • Relevant failure modes: • The STO trips spuriously (safe failure) • The STO does not activate when requested • A fault exclusion on the failure mode “short circuit on printed circuit board”...

  • Page 268: Tüv Certificate

    268 The Safe torque off function Term or Reference Description abbreviation IEC 61508-6 Proof test interval. T is a parameter used to define the probabilistic failure rate (PFH or PFD) for the safety function or subsystem. Performing a proof test at a maximum interval of T is required to keep the SIL capability valid.

  • Page 269: Internal Cooling Circuit

    Each cubicle has an inlet and an outlet manifold, fitted with a stop valve and a drain valve. The stop valves can be closed to isolate all modules in the cubicle from the main cooling circuit. In cabinet line-ups built by ABB, valves are color-coded: • Blue – Open during operation •...
  • Page 270 270 Internal cooling circuit Supply modules. The drawing shows the configuration of a diode supply unit with two modules, ie. there is a common air-to-liquid exchanger in the cubicle. With an IGBT supply unit, each module has a dedicated air-to-liquid exchanger as shown for item 2. Inverter modules To/From cooling unit Air-to-liquid heat exchanger...

  • Page 271: Connection To A Cooling Unit

    Internal cooling circuit 271 Connection to a cooling unit Connection to an ACS880-1007LC cooling unit ￭ Refer to ACS880-1007LC cooling unit user’s manual (3AXD50000129607 [English]). Connection to a custom cooling unit ￭ General requirements Equip the system with an expansion tank to damp pressure rise due to volume changes when the temperature varies.

  • Page 272: Filling Up And Bleeding The Internal Cooling Circuit

    272 Internal cooling circuit Filling up and bleeding the internal cooling circuit Both the drive and coolant must be at room temperature before filling up the cooling circuit. WARNING! Make sure that the maximum permissible operating pressure is not exceeded. When necessary regulate the pressure to appropriate level by draining excess coolant out of the system.

  • Page 273: Draining The Internal Cooling Circuit

    Internal cooling circuit 273 Close the bleed valve at the cooling unit. 10. Continue to fill in coolant until a base pressure of approximately 250 kPa is achieved. 11. Open the bleed valve of the pump to let out any air. 12.

  • Page 274: Technical Data

    Coolant type Antifrogen® L (by Clariant International Ltd, www.clariant.com) 25% or 50% mixture, available from Clariant distributors and ABB Service representatives. Do not dilute the coolant. It is ready to use. Antifrogen® L 25% mixture is usable in storage temperatures down to -16 °C (3.2 °F).
  • Page 275 Internal cooling circuit 275 be derated by 6 percentage points per 1 °C (1.8 °F) temperature increase, as shown by curve (c). • If there are no components with a maximum operating temperature of 55 °C (131 °F) installed in the same space as the drive modules, drive output current must be derated by 2 percentage points per 1 °C (1.8 °F) temperature increase, as shown by curve (b).

  • Page 276: Pressure Limits

    276 Internal cooling circuit Maximum temperature rise: Depends on heat losses and mass flow. Typically 10 °C (18 °F) with nominal losses and flow. Pressure limits ￭ Note: The pressure limits for ACS880-1007 cooling units manufactured before week 24 of 2020 are given in ACS880-1007LC user's manual, revision C. Base pressure: 250 kPa (recommended);...

  • Page 277: Resistor Braking

    Resistor braking 277 Resistor braking The brake units available for the drive are: • Single-phase, on/off-controlled brake chopper indicated by option codes +D150 (chopper) and +D151 (resistors) • Three-phase ACS880-607LC 3-phase dynamic brake units with control of current and power by modulation. For more information, refer to •...

  • Page 279: Further Information

    Product and service inquiries Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to www.abb.com/contact-centers.
  • Page 280 3AXD50000131457C © Copyright 2024 ABB. All rights reserved. Specifications subject to change without notice.

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